Trailer

ABSTRACT

A trailer including an inner frame that is made of metal, an outer shell that is made of a non-metal and that at least partially surrounds the inner frame, and at least one wheel rotatably secured to the inner frame. In a preferred embodiment, the outer shell is made of a plastic. The inner frame includes a lower frame portion with which the at least one wheel is rotatably secured, and an upper frame portion that supports at least a portion of the weight of the outer shell. Preferably, the upper frame portion includes a middle support member that extends upwardly from the lower frame portion, and a first bar assembly that is hingedly connected to the middle support member. In another embodiment, a second bar assembly is hingedly connected to the middle support member.

This is a divisional of application Ser. No. 09/901,375 filed on Jul. 9,2001 now U.S. Pat. No. 6,575,523 which is a continuation application ofSer. No. 09/884,706 filed on Jun. 19, 2001, all of which areincorporated by reference in their entireties therein.

FIELD OF THE INVENTION

The present invention relates to a trailer, and more particularly to atrailer having an improved infrastructure and hatch latches.

BACKGROUND OF THE INVENTION

When going on a trip, such as a weekend trip, travelers often need morespace than is available in their car or truck. Trailers that are towedby a towing vehicle, such as a car or a truck, serve the purpose ofproviding extra space. However, trailers have several drawbacks. Firstof all, trailers are typically heavy and only capable of being towed bylarger vehicles. Trailers are also bulky and not very aerodynamic.

Accordingly, a long felt need exists for a trailer that is light,aerodynamic and versatile.

SUMMARY OF THE PREFERRED EMBODIMENTS

In accordance with a first aspect of the present invention there isprovided a trailer including an inner frame that is made of metal, anouter shell that is made of a non-metal and that at least partiallysurrounds the inner frame, and at least one wheel rotatably mounted tothe inner frame. In a preferred embodiment, the outer shell is made of aplastic. Preferably, the inner frame includes a lower frame portion withwhich the at least one wheel is rotatably mounted, and an upper frameportion that supports at least a portion of the weight of the outershell. Preferably, the upper frame portion includes a middle supportmember that extends upwardly from the lower frame portion, and a firstbar assembly that is hingedly connected to the middle support member. Inanother embodiment, a second bar assembly is hingedly connected to themiddle support member.

In a preferred embodiment, the upper frame portion further includesfront and rear support members that are connected to the middle supportmember by elongated members and that support at least a portion of theweight of said upper body portion. The outer shell includes an upperbody portion and a lower body portion that includes front and rear lowersections. Preferably, the outer shell includes a first cover thatincludes an outer skin and an inner skin, and that has a first barassembly disposed between the inner skin and the outer skin. In oneembodiment, the first bar assembly is made of a metal and the inner andouter skins are made of a non-metal, such as a plastic. The outer shellcan also include a second cover. In a preferred embodiment, the firstand second covers are pivotally connected to the outer shell by at leastone hinge that is connected to the first and second bar assembliesthrough the outer skin of the covers.

In a preferred embodiment, the trailer includes an inner liner that hasa bottom and a wall extending upwardly from the bottom at an angle θ.Preferably the wall terminates in a lip that is affixed to the outershell.

In accordance with another aspect of the present invention there isprovided a hinge that includes a middle portion having first and secondopposite ends, a front hinge portion and a rear hinge portion. Themiddle portion has at least one end member extending outwardly from itsfirst end and at least one end member extending outwardly from itssecond end. Each end member has an opening defined therethrough. Thefront and rear hinge portions each have at least one end member with anopening defined therethrough extending outwardly from an end thereof.The opening in the end member of the first end of the middle portioncooperates with the opening in the end member of the front hinge portionto receive a first hinge pin. The opening in the end member of thesecond end of the middle portion cooperates with the opening in the endmember of the rear hinge portion to receive a second hinge pin. In amuch preferred embodiment, the middle portion and/or the front and rearhinge portions have openings defined laterally therethrough. Theopenings may be used for attaching racks or the like to the hinge.

In accordance with another aspect of the present invention there isprovided a hinge including a middle portion and a cover portion. Themiddle portion has an opening defined laterally therethrough and atleast one end member having an opening defined therethrough extendingoutwardly from an end thereof. The hinge portion has at least one endmember having an opening defined therethrough extending outwardly froman end thereof. The opening in the at least one end member of the middleportion cooperates with the opening in the at least one end member ofthe hinge portion to receive a hinge pin. In a much preferredembodiment, the middle portion and hinge portion are made using anextrusion process.

In accordance with another aspect of the present invention there isprovided a trailer including a main body portion, at least one wheelrotatably secured to the main body portion, and a cover hingedlyconnected to the main body portion. The cover includes an inner skin, anouter skin, and a bar assembly disposed between the inner and outerskins. In a preferred embodiment, the cover is hingedly secured to themain body portion and the bar assembly includes mounting brackets towhich the hinge is secured to mount the cover.

In accordance with yet another aspect of the present invention there isprovided a trailer including an inner frame having lower and upper frameportions and an outer shell and at least one wheel rotatably secured tothe lower frame portion of the inner frame. The outer shell at leastpartially surrounds the inner frame and includes an upper body portionand lower body portion that are bonded together. The upper body portionrests on the inner frame and the lower body portion. The lower frameportion includes an axle that has a pair of wheels rotatably secured atopposite ends thereof. Most preferably, the axle is a torsion axle. In apreferred embodiment, the upper body portion has first and second coversassociated with first and second openings defined in the upper bodyportion. The upper body portion also includes an arch portion extendingbetween and partially defining the first and second openings. The archportion rests on the upper frame portion. A hinge pivotally connects thefirst and second covers to the outer shell and is secured to the upperframe portion through the arch portion.

In a preferred embodiment, the inner skin of the first and second coverseach include a latch depression for receiving a latching system therein.The latching system preferably includes at least one connector that isadapted to engage a keeper on the front and rear support members whenthe first and second covers are closed. Preferably, the lower bodyportion includes a lip defined around a top edge thereof and the upperbody portion includes a lower edge that is adapted to cooperate with thelip, thereby forming the outer shell. The upper and lower body portionscan be secured to one another using, for example, an adhesive tape.

In accordance with another aspect of the present invention there isprovided a method of propping open a cover. The method includes thesteps of unlatching a hook associated with the cover from a keeper,raising the cover unlatching a prop rod from the cover, pivoting theprop rod downwardly, and engaging the prop rod with the keeper.

In accordance with another aspect of the present invention there isprovided a trailer that includes a trailer body, a first cover hingedlyconnected to the trailer body, and a first prop rod secured to the firstcover. The prop rod is adapted to be pivoted downwardly and engage thetrailer body, thereby propping the cover open. In another embodiment,the trailer can include a second cover and a second prop rod.

In accordance with yet another aspect of the present invention there isprovided a prop rod for propping open a cover that includes an elongatedrod having first and second opposite ends, a hook at the first end, anda loop secured to an eye hook at the second end. Preferably the innersurface of the hook has at least one notch defined therein.

In accordance with a further aspect of the present invention there isprovided a trailer including a lower frame portion, a lower body portionsupported on the lower frame portion, an upper frame portion extendingupwardly from the lower frame portion, and an upper body portionsupported on the upper frame portion and affixed to the lower bodyportion. The lower frame portion includes at least one axle havingwheels at its opposite ends. In a preferred embodiment, the lower bodyportion has a lip extending inwardly from a bottom edge thereof. A floorpanel is disposed between the lower frame portion and the lower bodyportion. The floor panel has a lip extending around at least a portionof the perimeter thereof that is affixed to the lip of the lower bodyportion. A preferably wooden deck is disposed between the lower frameportion and the floor panel.

In a preferred embodiment, the floor panel has at least two wheelcavities defined therein and the floor panel has at least two wheelhousings secured thereto. The wheel cavities and the wheel housingscooperate to partially surround the wheels. The lower frame portionpreferably includes a plurality of frame horns affixed thereto. Theupper frame portion extends upwardly from the frame horns.

In accordance with yet another aspect of the present invention there isprovided an inner frame for a trailer that includes a lower frameportion, front, middle and rear support members extending upwardly fromthe lower frame, a first bar assembly hingedly connected to the middlesupport member, and a second bar assembly hingedly connected to themiddle support member.

In accordance with still another aspect of the present invention thereis provided a trailer including a lower frame portion, a tub-shapedinner liner supported on the lower frame portion, a lower body portionat least partially surrounding the inner liner and supported on thelower frame portion, and an upper body portion secured to the lower bodyportion. The inner liner has a lip running around a top edge thereofthat is secured to an inside surface of the upper body portion.

In accordance with another aspect of the present invention there isprovided an inner liner including a bottom having an outer edge and aplurality of ribs defined therein, a wall extending upwardly from theouter edge of the bottom, and a lip extending from the top edge of thewall. The wall has at top edge and at least two opposing wheel cavitiesdefined therein.

In another preferred embodiment of the invention, there is provided adrain including a cylindrical extension portion having a top and abottom, wherein the extension portion has an opening definedtherethrough, and a cylindrical shaped upper portion having a top and abottom. The upper portion has a flange extending radially outwardly fromthe top thereof. The upper portion is received in the opening of theextension portion. The flange is located above the top of the extensionportion, and the bottom of the extension portion is located below thebottom of the upper portion. Preferably the extension portion is taperedsuch that the opening is wide at the top and is narrow at the bottomthereof.

Other objects, features and advantages of the present invention willbecome apparent to those skilled in the art from the following detaileddescription. It is to be understood, however, that the detaileddescription and specific examples, while indicating preferredembodiments of the present invention, are given by way of illustrationand not limitation. Many changes and modifications within the scope ofthe present invention may be made without departing from the spiritthereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more readily understood by referring to theaccompanying drawings in which

FIG. 1 is a perspective view of a trailer with the front and rear coversclosed in accordance with a preferred embodiment of the presentinvention.

FIG. 2 is a perspective view of the open cover of the trailer of FIG. 1showing a latch system in accordance with a preferred embodiment of thepresent invention.

FIG. 3 is a perspective view of the open cover of a trailer showing thelatch system of FIG. 2 with a cover member, in accordance with anotherpreferred embodiment of the present invention.

FIG. 4 is an exploded perspective of the latch plate assembly of FIG. 2.

FIG. 5 is an exploded perspective view of the shaft assembly, latchplate assembly and keepers of the latch system of FIG. 2.

FIG. 6 is a sectional side elevation of the shaft assembly and the latchplate assembly of FIG. 2 in a retracted/unlatched position.

FIG. 7 is a sectional side elevation of the shaft assembly and the latchplate assembly of FIG. 2 in a latched/closed position.

FIG. 8 is a side elevation of the latch system of FIG. 2 in aretracted/unlatched position.

FIG. 9 is a side elevation of the latch system of FIG. 2 in alatched/closed position.

FIG. 10 is an exploded perspective of the components of the trailer ofFIG. 1, including the inner frame, deck, floor panel, inner liner, lowerand upper body portions, front and rear covers, and hinges.

FIG. 11 is an exploded perspective of the inner frame of the trailer ofFIG. 1.

FIG. 12 is a perspective view of the lower frame portion of the trailerof FIG. 1.

FIG. 13 is a perspective view of a the tubular member, square shaft andelastomeric pieces of the torsion axle in accordance with a preferredembodiment of the present invention.

FIG. 14 is a cross-sectional view of a portion of the torsion axle takenalong line 14—14 of FIG. 13.

FIG. 15 is a cross-sectional view of a portion of the torsion axle takenalong line 15—15 of FIG. 14, showing the square shaft at a position ofrest.

FIG. 16 is a cross-sectional view similar to FIG. 15, but showing thesquare shaft in a torqued position.

FIG. 17 is a top plan view of the axle removed from the lower frameportion.

FIG. 18 is a side elevational view of the axle of FIG. 17.

FIG. 19 is a front elevational view (partially in section) of an end ofthe front (or rear) support members showing a clevis connection andtaken along line 19 of FIG. 21.

FIG. 20 is a side perspective view of the inner frame (with theelongated members removed), and the floor panel with the inner linerthereon.

FIG. 21 is a front perspective view of the inner frame and the floorpanel with the inner liner thereon.

FIG. 22 is a perspective view of the dual clevis connections on thebracket located on the middle support member of the inner frame.

FIG. 23 is an exploded perspective of the components shown in FIG. 22.

FIG. 24 is a perspective view of the lower frame with the deck thereon.

FIG. 25 is a perspective view of lower panel with one wheel housingsecured thereto.

FIG. 26 is a detailed perspective view of an attachment plate of themiddle support member exploded from an indented portion of the floorpanel.

FIG. 27 is a detailed perspective view of the front support memberexploded from two indented portions of the floor panel.

FIG. 28 is a top plan view of the trailer of FIG. 1 with the upper bodyportion (and covers) removed.

FIG. 29 is a perspective view of the trailer of FIG. 1 with the upperbody portion (with the covers removed) exploded from the lower bodyportion.

FIG. 30 is a perspective view of the rear of the trailer of FIG. 1 withthe rear cover open.

FIG. 31 is a rear elevational view of the trailer of FIG. 1 with theupper body portion removed.

FIG. 32 is a side elevational view of the trailer of FIG. 1 with theupper body portion removed.

FIG. 33a is a partial side sectional view of the trailer of FIG. 1showing the drain and how the front of the inner liner and upper andlower body portions are secured together.

FIG. 33b is a partial front sectional view of the trailer of FIG. 1showing the middle support portion and how the inner liner and upper andlower body portions are secured together.

FIG. 33c is a partial side sectional view of the trailer of FIG. 1showing the rear support member and how the rear of the inner liner andupper and lower body portions are secured together.

FIG. 34 is a front angle perspective view of the upper body portion inaccordance with a preferred embodiment of the present invention.

FIG. 35 is a rear angle perspective view of the upper body portion inaccordance with a preferred embodiment of the present invention.

FIG. 36 is a cross-sectional rear elevational view of a section of theupper body portion showing the water diversion trough.

FIG. 37 is a cross-sectional side elevational view of the trailer ofFIG. 1 taken along line 37—37 of FIG. 1.

FIG. 38 is a cross-sectional side elevational view of the trailer ofFIG. 1 taken along line 38—38 of FIG. 1.

FIG. 39 is a rear angle perspective view of the trailer of FIG. 1 withthe front and rear covers propped open.

FIG. 40 is an exploded perspective view of the rear cover showing theinner and outer skins, bar assembly and seal.

FIG. 41 is a partial sectional side elevation of the rear cover 111showing the latching system mechanically connected to a tab of the rearbar assembly.

FIG. 42 is a bottom plan view of the rear cover with a portion of theinner skin cut away to show the bar assembly.

FIG. 43 is a front angle perspective view of the trailer of FIG. 1 withthe front cover propped open.

FIG. 44 is an exploded perspective of the front cover showing the innerand outer skins, bar assembly and seal.

FIG. 45 is a bottom plan view of the front cover with a portion of theinner skin cut away to show the bar assembly.

FIG. 46 is a perspective view of the top of the trailer of FIG. 1showing the hinges hingedly connecting the front and rear covers to thearch portion.

FIG. 47 is an exploded perspective view of a hinge showing the middleportion and front and rear hinge portions.

FIG. 48a is a bottom plan view of a hinge in accordance with a preferredembodiment of the present invention.

FIG. 48b is a side elevational view of the hinge of FIG. 48a includingphantom depictions of the front and rear hinge portions that show thepreferred angle that they can hinge.

FIG. 48c is a detailed view of the portion of the hinge where the middleportion connects to the front hinge portion showing the set screw.

FIG. 48d is a cross-sectional view of the set screw and bushings of thehinge of FIG. 48a taken along line 48 d—48 d of FIG. 48c.

FIG. 49 is a cutaway top plan view of a portion of the arch portion andfront and rear covers with the hinge removed to show the openings and aspacer thereunder.

FIG. 50 is a cut away perspective view of the underside of the frontcover showing the prop rod secured thereto.

FIG. 51 is a detailed perspective view of the ball joint of the frontprop rod pivotally connected to an attachment plate on the underside ofthe front cover.

FIG. 52 is a detailed perspective view of a rod securing hook securingthe elongated rod of front prop rod to the underside of the rear cover.

FIG. 53 is a detailed perspective of the hook of the front prop rodsecured in place by a rod securing hook.

FIG. 54 is a rear angle perspective view of the trailer of FIG. 1 withthe rear cover propped open.

FIG. 55 is a cut away perspective view of the underside of the rearcover showing the prop rod secured thereto.

FIG. 56 is a detailed perspective view of the ball joint of the rearprop rod pivotally connected to the mounting bracket (of the barassembly) on the underside of the rear cover.

FIG. 57 is a detailed perspective view of a rod securing hook securingthe elongated rod of rear prop rod to the underside of the rear cover.

FIG. 58 is a detailed perspective of the hook of the front prop rodsecured against a skid plate on the underside of the rear cover.

FIG. 59 is a detailed perspective showing the hook of the rear prop rodengaged with a keeper in accordance with a preferred embodiment of thepresent invention.

FIG. 60 is a side elevational view of a prop rod having a ball joint atan end thereof in accordance with a preferred embodiment of the presentinvention.

FIG. 61 is a detailed perspective view of and end of the front prop rodpivotally secured to an eye hook that is connected to an attachmentplate on the underside of the front cover in accordance with anotherpreferred embodiment of the present invention.

FIG. 62 is a block diagram of a towing vehicle in combination with atrailer having a low current tow vehicle-powered supplemental lightingsystem in accordance with a preferred embodiment of the presentinvention.

FIG. 63a is a schematic of a light comprised of a plurality of lightemitting diodes, showing a portion of them lit to indicate running.

FIG. 63b is a schematic of a light comprised of a plurality of lightemitting diodes, showing a portion of them lit to indicate turning.

FIG. 64a is a top plan view of the trailer of FIG. 1 with the upper bodyportion and inner liner removed to show the path of the lighting wires.

FIG. 64b is a detailed top plan view of the front right side markerlight.

FIG. 64c is a detailed top plan view of the rear right brakelight/taillight/turnlight.

FIG. 64d is a detailed top plan view of the rear left side marker light.

FIG. 64e is a sectional elevational view of a portion of the inner linerand lower frame portion showing the raised ribs of the inner liner and alight wire running through one of the raised ribs.

Like numerals refer to like parts throughout the several views of thedrawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Described herein are preferred embodiments of a trailer that includes aplurality of novel components, including, without limitation, a latchingdevice for latching shut the free end of a trailer or vehicle cover,e.g., a trunk, cover, door or the like; a hinge; a prop rod system and amethod of making the trailer. It will be understood that the use of thevarious components of the trailer, such as the latching device, thehinge, the prop rods, etc. is not limited to use on a trailer orvehicle. Other uses of these components will be readily apparent tothose skilled in the relevant art, and such uses are within the scope ofthe present invention. The description of these components herein asused with a trailer/vehicle is only exemplary and not limiting.

It will be appreciated that terms such as “upper,” “inner,” “outer,”“vertical,” “horizontal,” “bottom,” “below,” “top,” “side,” “inwardly,”“outwardly,” “downwardly” and “lower” and other positionally descriptiveterms used hereinbelow are used merely for ease of description and referto the orientation of the components as shown in the Figures. It shouldbe understood that any orientation of components of the trailerdescribed herein is within the scope of the present invention. Asillustrated in FIG. 1, to aid in the description and understanding ofthe invention, the trailer defines a “longitudinal axis” that extends ina direction parallel to that which the trailer travels; a “lateral axis”that is perpendicular to the longitudinal axis and extends in adirection from one side of the trailer to the other; and a “transverseaxis” that is perpendicular to the longitudinal axis and extends in anup and down direction.

As shown in FIGS. 1 and 39, the trailer 100 of the present inventiongenerally includes front and rear covers or doors 110, 111, a main bodyportion 114, a tongue 102 and a pair of wheels 150. Each door 110, 111includes a latching system 10 for securing the door to the main body ofthe trailer 100.

Referring to FIGS. 2-3, a preferred embodiment of the door latchingsystem 10 is shown. The latching system 10 generally includes a hingedlatch plate assembly 12 secured to a shaft assembly 14 a portion ofwhich is in rotational cooperation with the hinged latch plate assembly12, and a pair of keepers 16 affixed to the sill 112 of the main bodyportion 114.

Referring to FIG. 4, the latch plate assembly 12 generally includes abase plate 18, handle 20, latch lever 22 and beak member 24. The baseplate 18 includes a first set of opposed members 26 having openings 28defined therein for receiving a handle pivot pin 30. The handle 20 alsoincludes opposed members 32 having openings 34 defined therein. Thelatch lever 22 has an opening 35 defined therethrough for receiving thehandle pivot pin 30 and a pair of openings 36 defined therethrough forreceiving threaded fasteners 37 for securing the latch lever 22 to thehandle 20.

In assembling the latch plate assembly 12, the handle pivot pin 30extends through openings 34 in the handle 20, openings 28 in the baseplate 18 and opening 35 in the latch lever 22. The handle pivot pin 30can be secured in place in a number of different ways. For example, thehandle pivot pin may be a bolt secured in place by a nut or it mayinclude a keyway defined therein and be secured in place via a set screwor the like. As shown in FIG. 4, base plate 18 has a recess 38 thatreceives a portion of the latch lever 22, and allows the latch lever 22to rotate relative to base 18. Preferably, the handle pivot pin 30 has atorsion spring 39 thereon to hold the handle 20 (when in the openposition) at an angle (preferably approximately a 45° angle) to preventunintentional engagement of the beak member 24 if the cover 110/111should accidentally drop shut.

Base plate 18 also includes a plurality of apertures 40 definedtherethrough for receiving a plurality of threaded fasteners 41 or thelike for securing the base plate 18 to the shaft assembly 14. It will beunderstood that any method for securing the base plate 18 to the shaftassembly 14 is within the scope of the present invention. For example,the base plate 18 can be secured to the shaft assembly 14 by rivets,welding, gluing or the like.

Base plate 18 includes a second set of opposed members 42 havingopenings 44 defined therethrough for receiving a beak pivot pin 46.Preferably, the second set of opposed members 42 are located at an endof base plate 18 opposite that of the first set of opposed members 26.In a preferred embodiment, the beak pivot pin 46 is an elongated bolthaving a nut 46 a for securing the elongated bolt in place. The beakmember 24 includes a main body portion 24 a through which an opening 24b extends and a beak 24 c. The beak pivot pin 46 extends throughopenings 44 in the base plate 18 and opening 24 b in the beak member 24.The beak pivot pin 46 includes a torsion spring 48 or the like thereonfor urging the beak member 24 into latched engagement with a strikerplate 54, which is secured to handle 20 (as described more fullyhereinbelow).

Handle 20 includes a handhold end 20 a and a hinge end 20 b. Thehandhold end 20 a preferably has serrations thereon for ease ofgripping. Defined preferably in a central portion of the handle 20 is anelongated opening 50 having two pairs of apertures 52 defined onopposite sides thereof. The elongated opening 50 is adapted to receivethe beak member 24. Apertures 52 receive threaded fasteners 41 or thelike for securing the beak striker plate 54 (via apertures 56) to thehandle 20. The beak striker plate 54 includes a striker portion 54 athat protrudes through elongated opening 50 and is oriented to beengaged by the beak member 24 when the latch plate assembly 12 is in aclosed/latched position. The striker portion 54 a includes a cam surface54 b that is engaged by the top of the beak member 24 when the latchplate assembly 12 is being closed. The curved shape of the cam surface54 b causes the beak member 24 to be urged inwardly during closing,thereby loading spring 48. As the beak member 24 reaches the end of thecam surface 54 b, the spring 48 is at least partially unloaded, and thebeak 24 c engages the striker portion 54 a. The latch plate assembly 12is now in the latched/closed position. As shown in FIG. 4, the apertures56 of the beak striker plate 54 correspond to one of the pairs ofapertures 52 in the handle 20. Accordingly, threaded fasteners 37 arereceived therein for securing the beak striker plate 54 to the handle20.

In a preferred embodiment, the beak is made of aluminum and provides abreakaway feature so that if a vandal attempts to break the into thetrailer by prying against handle 20, the beak 24 will break withoutcausing harm to any of the other components. Therefore, the beak 24 canbe replaced without having to replace any other parts.

Referring to FIG. 5, the shaft assembly 14 generally includes innershield members 58, an outer shield member 60, an elongated member orshaft 62 having a rotator clevis 64 thereon and a pair of hooks 66preferably, disposed at the ends of the elongated shaft 62. It will beappreciated by those skilled in the art that a number of differentcomponents can be substituted for the elongated member 62. For example,without limitation, the elongated member 62 can be a shaft, rod, tube,channeled member, etc. Throughout the specification and figures, anelongated shaft is shown. However, this is not a limitation on thepresent invention. It will also be appreciated by those skilled in theart that a number of different components can be substituted for theconnectors 66. For example, without limitation, the connectors 66 can behooks, clamps, clasps, magnets, buttons, snaps, latches, pins, etc.Throughout the specification and figures, hooks are shown. However, thisis not a limitation on the present invention.

The outer shield member 60 is adapted to be affixed to the underside(and preferably in the latch depression 188 b of the inner skin 188) ofthe front or rear cover 110, 111 (the front cover 110 is used herein forexemplary purposes). It will be understood that the outer shield member60 provides an anchor for attaching the shaft assembly 14 to the frontcover 110. Any method for attaching the shaft assembly 14 to the frontcover 110 is within the scope of the present invention.

The inner shield members 58 are secured to the outer shield member 60 inspaced relation to one another. Preferably, the inner shield members 58are secured to the outer shield member 60 via threaded fasteners 41(either within tapped holes in outer shield member 60 or using nuts).This allows the shaft assembly 14 to be disassembled for maintenance.However, any method of securing the inner shield members 58 to the outershield member 60 (i.e., welding, gluing, etc.) is within the scope ofthe present invention. The gap formed between the inner shield membersis to accommodate the rotator clevis 64 as described below. The innershield members 58 have a semi-tubular portion 58 a formed therein andthe outer shield member 60 has a semi-tubular portion 60 a formedtherein. When the inner shield members 58 are secured to the outershield member 60 the semi-tubular portions 58 a and 60 a cooperate toform a tube through which the elongated shaft 62 extends. In anotherembodiment, the elongated shaft 62 can extend through a tube or a pairof tubes that are welded or otherwise secured to the outer shield member60.

In a preferred embodiment, as best shown in FIG. 6, the inner shieldmembers 58 include a tab portion 58 b that is adapted to be received ina corresponding tab receiving portion 60 b defined in the outer shieldmember 60. When the inner shield members 58 are secured to the outershield member 60, the tab portion 58 b is received in the tab receivingportion 60 b, thereby helping to align the semi-tubular portions 58 aand 60 a and helping secure the inner shield members 58 to the outershield member 60.

Referring again to FIG. 5, the rotator clevis 64 is comprised of a tube72 having a pair of spaced forks 74 extending therefrom. The hooks 66are comprised of a tube 66 a having a hook member 66 b extendingtherefrom and preferably are disposed at or adjacent to opposite ends ofthe elongated shaft 62. In a preferred embodiment, the hooks 66 aresecured to the elongated shaft 62 by roll pins 67. The hooks can also besecured via a set screw(s) or the like. The hooks 66 may also be weldedto the elongated shaft 62 or the hooks 66 and elongated shaft 62 may beformed as a unit.

As described above, the elongated shaft 62 extends through the tube(referred to herein as 72) formed by cooperating semi-tubular portions58 a and 60 a. In a preferred embodiment, the tube 72 includes aplurality of bushings 73 therein for supporting the elongated shaft 62(see the Figures for the preferred placement of bushings 73). Therotator clevis 64 is preferably secured to the elongated shaft 62 by aset screw 67 or a roll pin. The elongated shaft 62 includes apertures orindentations for receiving the set screws 67. In another embodiment, theelongated shaft 62 and the rotator clevis 64 can be formed as a unit orcan be welded or otherwise adhered together.

As shown in FIG. 2, the inner shield members 58, 60 are spaced apart toform an opening 76 for receiving the rotator clevis 64 therein. Asdescribed below, in operation, the elongated shaft 62 rotates withintube 72, relative to the inner and outer shield members 58 and 60. Theopening 76 allows the rotator clevis 64 to rotate as necessary.

Referring to FIGS. 7-9, the latch lever 22 includes an engagement member78 that extends through opening 76 and engages the rotator clevis 64.The engagement member 78 preferably includes a pair of opposed knobs 78a extending laterally therefrom. The opposed knobs 78 a are eachreceived in the opening 74 a defined within each of the forks 74.

The outer shield member 60 also has a plurality of apertures 79 (asshown in FIG. 5) for receiving the plurality of threaded fasteners 41 orthe like for securing the base plate 18 to the shaft assembly 14 asdescribed above. A spacer 81 can be placed on threaded fastener 41 tospace the outer shield portion 60 from the base plate 18. In oneembodiment of the invention, the front cover 110 can include aprotection member 116 (see FIG. 3) that substantially encloses the shaftassembly 14, but has openings defined therein for allowing the hooks 66to extend therethrough for engagement with the keepers 16.

Referring again to FIGS. 2 and 5, the keepers 16 generally include amain body portion 80, a tubular portion 83 and a hook receiving opening82. The keepers are secured to the sill 112 of the main body portion 114by threaded fasteners 41. Any securing method is within the scope of theinvention. The keepers 16 are positioned on the sill 112 so that theycorrespond to the hooks 66 when the front cover 110 is closed.

Preferably, the components of the latching system are made of a rigidmaterial such as a metal. However, the type of material used is not alimitation on the present invention. In a preferred embodiment, many ofthe components of the latching system (the handle, the inner and outershield members, the base plate) are made using an extrusion processinstead of a casting process (however casting can be used if desired)for efficiency and limitation of manufacturing costs.

The operation of the latching system 10 will now be described. It willbe understood that the front cover 110 has an open position where thecover 110 is spaced above the main body portion 114 and a compartment118 defined within the main body portion 114, and a closed positionwhere the cover 110 engages the main body portion 114. It will befurther understood that the latching system 10 has a retracted/unlatchedposition and a closed/latched position. In general, hinged operation ofthe handle 20 causes movement of the latch lever 22 which in turn drivesrotational movement of the hooks 66 via rotation of the rotator clevis64 and elongated shaft 62.

The front cover 110 preferably defines a cavity 186 a therein forreceiving the handle 20. When the handle is in the closed/latchedposition, the handle is substantially flush with the top surface of thefront cover 110. FIG. 2 shows the latch system 10 in the retractedunlatched position and the front cover 110 in the open position with theprotection member 116 removed FIG. 3 shows the protection member 116 inplace, in accordance with another preferred embodiment). To latch thelatching system 10, the front cover 110 is closed, such that the hooks66 and keepers 16 are in close proximity. The handle 20 is then hingedor pivoted inwardly (see arrow A in FIG. 8), relative to the base plate18. This movement urges the latch lever 22 generally in the same arcuatedirection as the hand-hold end handle 20 pivots (see arrow A in FIG. 8).Latch lever 22 moves within opening 76 between the inner shield members58 and recess 38 in the base plate 18. The movement of the latch lever22, the knobs 78 a of which are engaged within the forks 74 of therotator clevis 64, causes rotational movement of the rotator clevis 64(see arrow C in FIG. 8), the elongated shaft 62 and ultimately thehorizontally spaced hooks 66 on the ends of the elongated shaft 62 (seearrow B in FIG. 8). The rotation of the hooks 66 causes the hook member66 b to be received in the hook receiving opening 82 of the keepers 16,thereby latching the front cover 110 to the main body portion 114. Itwill be understood that the hooks 66 rotate in an arcuate direction (seearrow B in FIG. 8) substantially opposite of arrow A. It will beunderstood that the arrows in FIG. 8 illustrate the rotational directionof the components when the latching system 10 is being closed, and thearrows in FIG. 6 illustrate the rotational direction of the componentswhen the latching system 10 is being opened.

In a preferred embodiment, there is a resilient compressible material orseal 108 (see FIG. 38) provided between the main body portion 114 andthe front cover 110. It will be understood that the seal 108 can bedisposed on the main body portion 114 or the front cover 110 (or therear cover 111). As the hooks 66 engage the keepers 16, the keepers 16are oriented such that the inner surface of the hook member 66 b engagesa tubular portion 83 of the keeper 16. As the hook further enters thehook receiving opening 82, the force of the hook member 66 b against thetubular portion 83 increases, thereby compressing the resilient materialand sealing the compartment 118.

As the handle 20 is hinged toward the closed position (with enough forceto overcome the urging of the torsion spring 39 and the friction betweenthe cam surface 54 b and the beak member 24), the beak member 24 isreceived in the elongated opening 50 of the handle 20. As the beak 24 cpasses through the elongated opening 50, the spring 48 urges the beak 24c into engagement with the beak striker plate 54 as described above. Itwill be appreciated by those skilled in the art that the elements of thelatch plate assembly 12 are dimensioned such that when the handle 20 isin its closed/latched position, the beak 24 c engages the beak strikerplate 54 and holds the latch plate assembly in its closed/latchedposition. In a preferred embodiment, the beak member 24 has a lockopening 24 b defined therethrough for receiving a padlock or the likeand preventing unauthorized unlatching of the latching system 10 andopening of the front cover 110.

Referring to FIGS. 1 and 10-19, main body portion 114 includes a frame122, a deck 124, a floor panel 126, wheel housings 128, an inner liner130, a lower body portion 132 (having a front and a rear section 132 a,132 b) and an upper body portion 134.

As shown in FIG. 11, the frame 122 includes lower frame portion 136 anda plurality of support members 138. The lower frame portion 136 supportsa substantial amount of the weight of the overall trailer 100. Lowerframe portion 136 preferably has a plurality of framehorns 140 extendingtherefrom. The frame horns 140 provide mount/support points for thesupport members 138. In a preferred embodiment, the support members 138include attachment plates 142 at the ends thereof that have openings 142a defined therein through which threaded fasteners 37 extend. Thethreaded fasteners 37 also extend through corresponding openings 126 ain the floor panel 126 and are received in corresponding openings 140 ain the frame horns 140 and are secured therein with nuts, therebysecuring the support members 138 to the lower frame portion 136. It willbe understood that any method for connecting the support members 138 tothe frame horns 140 or the lower frame portion 136 is within the scopeof the present invention.

As shown in FIG. 12, the lower frame portion 136 also includes aplurality of perimeter holes 137 defined therein. The perimeter holes137 align with similar perimeter holes 137 in the floor panel 126, deck124 and the inner liner 130. Threaded fasteners 137 extend through thealigned perimeter holes 137, and are secured in place (either by a nutor a tapped perimeter hole 137), thereby securing the inner liner 130 tothe floor panel 126, deck 124 and the lower frame portion 136.

The lower frame portion 136 also includes an axle 144 mounted thereto(in another embodiment the lower frame portion 136 may include aplurality of axles) that spans the lower frame portion 136 in a lateraldirection. The axle 144 includes hubs 148, wheels 150 and tires 152,etc. on the ends thereof, as is known in the art. Preferably the axle144 is a torsion axle, which provides suspension to the trailer 100. Inone embodiment, as shown in FIGS. 13-16, the torsion axle 144 includes atubular member 154 having a square cross section, a square shaft 156that extends therethrough (but that is rotated approximately 45°relative to the tubular member, as shown in FIG. 15), and fourelastomeric pieces 158 inserted between the sides of the square shaft156 and the inner surfaces of the tubular member 154. A pair of spindlearms 160, to which the hubs 148 are attached, extend from the ends ofthe square shaft 156. The elastomeric pieces 158 are preferably placedin a state of compression during assembly. In operation, when thetrailer 100 goes over a bump and the wheels 150 go up and down, thespindle arms 160 cause the square shaft 156 to rotate (and assume atorqued position). The elastomeric pieces 158 are further compressed (asis shown in FIG. 16), thereby dampening the load and absorbing the shockcaused by the bump. In another embodiment, the elastomeric pieces 158can be bonded directly to the square shaft 156. In a preferredembodiment, the axle 144 is mounted to the lower frame portion 136 withthe spindle arm extending forwardly so that upward movement of thesuspension arm tends to relieve weight on the coupler 102 a, rather thanto increase it as is typical of the common rearward extending torsionaxle spindle arm.

The lower frame portion 136 also includes the tongue 102 having acoupler 102 a (such as a hitchball coupler) extending forwardlytherefrom. The tongue 102 may include a jack or other similar liftingdevice or brakes or wires, etc. thereon.

The frame 122 preferably includes front, middle and rear support members138 a, 138 b and 138 c that are attached longitudinally by elongatedmembers 162. As shown in FIG. 11, the elongated members 162 can have aslight bend formed therein to extend between support members 138 in adesirable manner and within the confines of the body shape. It will beunderstood that the support members are referred to generically as 138,the front support member is referred to as 138 a the middle supportmember is referred to as 138 b and the rear support member is referredto as 138 c. As shown in FIG. 11, the front support member 138 a extendsupwardly from the frontmost frame horns 140 and includes upright framemembers 146 (the attachment plates 142 are attached to the ends of theupright frame members 146) and a support portion 147. Preferably, theupright frame members 146 of the front support member 138 a extendthrough a pair of openings in the inner liner 130. The support portions147 have attachment points 164 at their opposite ends for the elongatedmembers 162. In a preferred embodiment, the attachment points 164comprise flanges 164 a that extend downwardly at each end. The flanges164 a have openings or slots 164 b therein that receive the threadedstud 166 a of a bifurcated attachment member 166. The opposing members166 b of the bifurcated attachment member 166 have openings thereinthrough which a threaded fastener 37 extends, thereby securing the endof the elongated member 162 therebetween, as is shown in FIG. 19. Thistype of connection allows acts as a joint and allows the elongatedmember 162 to pivot about threaded fastener 137 if necessary. This typeof connection is referred to herein as a bifurcated connection. As shownin FIG. 20, The support portion 147 also has at least two slots 147 aformed therein for securing the keepers 16 thereto.

The rear support member 138 c, which is similar to the front supportmember 138 a, extends upwardly from the rearmost frame horns 140 andincludes upright frame members 146 (the attachment plates 142 areattached to the ends of the upright frame members 146) and a supportportion 147 that has attachment points 164 at its opposite ends for theelongated members 162. In a preferred embodiment, the attachment points164 comprise flanges 164 a that extend downwardly at each end. Theflanges 164 a have openings or slots 164 b therein that receive thethreaded stud 166 a of a bifurcated attachment member 166, as best shownin FIG. 19. In a preferred embodiment, the elongated members 162 aresecured to each of the support members 147 via bifurcated connections.However, it will be understood that any method for securing theelongated members 162 to the support members 147 at the attachment point164, such as welding, gluing, etc., is within the scope of the presentinvention.

Referring to FIGS. 20-23, the middle support member 138 b preferablycomprises an arc-shaped member that has attachment plates 142 at itsends that engage the middle two frame horns 140. In a preferredembodiment, the middle support member 138 b includes support legs 138 dat its ends. The support legs 138 d have a smaller diameter than theremainder of the middle support member 138 b and are received therein. Athreaded fastener 37 or the like is inserted through aligned openings inthe middle support member 138 b and support leg 138 d to secure the twocomponents to one another (see FIG. 33b). The attachment plates 142 arelocated at the end of the support legs 138 d.

Referring to FIGS. 22-23, the middle support member 138 b includes, inat least two places along the longitudinal extent thereof, a clamp 168for securing an end of an elongated member 162. The clamp 168 ispreferably welded to the middle support member 138 b and has twoopenings 168 a defined therein through which the threaded stud 166 a ofa bifurcated attachment member 166 extends (and which is secured thereinusing a nut), thereby providing a bifurcated connection point for theelongated members 162. In a preferred embodiment, there are twoelongated members 162 extending between the middle support member 138 band the rear support member 138 c, and two elongated members 162extending between the middle support member 138 b and the front supportmember 138 a.

Referring again to FIGS. 20 and 21, the middle support member 138 b hasat least one, and preferably two, mounting brackets or mounting surfaces169 attached to the top thereof for supporting the upper body portion134. In a preferred embodiment, the mounting surface 169 comprises abracket that is affixed to the top of the middle support member 138 band is positioned to support the weight of the upper body portion 134.Any number of support members 138 or mounting brackets 169 is within thescope of the present invention.

Preferably, all of the components of the frame 122 (the lower frameportion 136, the support members 138, the frame horns 140, etc.) arecomprised of steel or other rigid metal or material, such as aluminum.The components of the frame 122 may also be made of a composite that isat least 50% metal, and more preferably 75% metal. However, the entireframe 122 or separate components thereof can be comprised of othermaterials such as a rigid plastic or the like. Also, various componentscan be affixed to one another by welding, gluing or with threadedfasteners or other conventional attachment or connection methods.Furthermore, the entire frame 122 or components thereof can be formed asone unit. It will be understood that the material used and the method ofaffixing components to one another are not intended to be limitations onthe present invention.

Referring to FIG. 24, the deck 124 is preferably comprised of wood andis secured on top of the lower frame portion 136 by threaded fasteners37. The deck 124 can also be comprised of a plastic or metal. The deck124 covers the open areas of the lower frame portion 136 and providessupport for the floor panel 126 and inner liner 130. The deck 124 ispreferably seal-coated with a sprayable urethane or the like that blocksabsorption of moisture. Perimeter openings 137 in the deck 124accommodate threaded fasteners 37. As described below, a center hole 124a allows a wire harness 176 to pass through from below the lower frame136 into the ribbed floor portion of the inner liner 130, as shown inFIG. 38.

Referring to FIGS. 25-27 the floor panel 126 is preferably made ofplastic and is formed to fit directly on top of the deck 124. The floorpanel 126 has a pair of wheel cavities 126 a defined therein. The floorpanel 126 also has a plurality of indented areas 126 b that are sized tocooperate with the attachment plates 142 of the support members 138. Theindented areas 126 b include openings 126 c therein that are coaxialwith the threaded members 37 of the attachment plates 142 and theopenings 140 a in the frame horns 140, as shown in FIG. 26.

The wheel housings 128, which are preferably made of plastic, are bondedto the floor panel 126 preferably by a double-sided adhesive tape (andare later bonded to the inner liner 130) and cooperate with the wheelcavities 126 a therein to provide a fender area in which the tire 152 ishoused when the trailer 100 is fully assembled.

Referring to FIGS. 20, 21 and 28, the tub-shaped inner liner 130 ispreferably made of plastic, is secured on top of the floor panel 126 andprovides the foundation for the reinforced structural shape that willevolve further as other plastic body parts are bonded into the assembly.Preferably, the inner liner 130 is both glued to and bolted to the floorpanel 126; however, any method of securing one to the other is withinthe scope of the present invention. The inner liner 130 also has wheelcavities 130 a formed therein that correspond to the wheel cavities 126a of the floor panel 126. In a preferred embodiment, the inner liner 130has raised parallel ribs 130 b formed therein which add stiffnessthereto and also support payload items in the storage compartment 118above water or other liquids that may have entered therein. A flange orlip 130 c extends around the top perimeter of the inner liner 130. Glueon this lip 130 c bonds the inner liner 130 to the upper body portion134. As will be described more fully below, the angular tub-shapedperimeter of the inner liner 130 bonds to other components to form astrong monocoque reinforcement around the trailer belt-line (or bumperarea, as described below), which often bears the brunt of accidentimpact, thereby adding structural stability to the trailer 100.

As shown in FIG. 20, the inner liner 130 includes close-out plugs 220 orgrommets that are preferably made of plastic in the openings throughwhich the middle support member 138 b and front support member 138 aextend. The tubing of the middle support member 138 b and front supportmember 138 a extend through the center opening of the close-out plug220.

As shown in FIG. 28, and as described above, threaded fasteners 37extend through the aligned perimeter holes 137 in the lower frameportion 136, deck 124, floor panel 126 and inner liner 130, and aresecured in place (either by a nut or a tapped perimeter hole 137),thereby securing the inner liner 130 to the floor panel 126, deck 124and the lower frame portion 136. Some of the threaded fasteners 37preferably include loops 37 a thereon (as shown in FIG. 33b) to allow arope to be received therein for tying down items in the storagecompartment 118. In a preferred embodiment, the loop 37 a comprises awasher that is received on the threaded fastener 37 and has a D-loopthat extends upwardly over the head of threaded fastener (see FIG. 33b).

As shown in FIG. 33a, in a preferred embodiment, the inner liner andfloor panel 12 have an opening defined therein, through which extends adrain 139. Any drain is within the scope of the present invention,however, in a preferred embodiment, the drain includes a cylindricallyshaped upper portion 139 a having a flange 139 b extending radiallyoutwardly therefrom for supporting the upper portion 139 a within theopenings and an extension 139 c with a flattened end that prevents flowof moisture from below while allowing drainage from the storagecompartment 118. As shown in FIG. 42a, the upper portion 139 a isreceived in the extension 139 c and inserted into the openings in theinner liner 130 and floor panel 126, such that the flange contact thefloor of the inner liner 130. Preferably the trailer includes two drains139. However, it will be understood that any number of drains 139 arewithin the scope of the present invention.

Referring to FIGS. 29-33c, the lower body portion 132 is preferablycomprised of a front section 132 a and a rear section 132 b. Having twoseparate sections makes assembly more efficient. However, the lower bodyportion 132 can be a single unitary piece. As shown in FIGS. 30-32, thefront and rear section 132 a, 132 b have formed therein lightdepressions 170 where stop/tail/turn lights 172 a, side marker lights172 b, license lights 172 c and rear reflectors 173 can be located. Thelights 172 are secured within the light depressions 170 by plasticpush-in fasteners, rivets, screws, other threaded fasteners or glue.Rear reflectors 173 are self-adhesive. The light depressions 170 have anopening defined therein for receiving a portion of the light and throughwhich the lighting wires 176 extend. It will be understood that thetrailer light wiring system runs from the lights 172 through the trailer100 via the hollow structures formed by the assembled body, for examplethrough a raised rib 130 b, as shown in FIG. 38, and forwardly insidethe tongue 102 and is adapted to be connected to a towing vehicle 178for energization. The preferred lighting system is more fully describedbelow.

As is shown in FIGS. 33a-33 c, the entire lower body portion 132 (bothfront and rear sections 132 a, 132 b) has an indented lip 132 cextending around a top edge thereof that is adapted to receive andpartially support the upper body portion 134. The upper body portion 134and inner liner 130 are attached to the lower body portion 132 (bothfront and rear sections 132 a, 132 b) at the indented lip 132 c.

The lower body portion also has an inwardly extending lip 132 d thatrests on a lip 126 d that extends outwardly from the floor panel 126.The lips 132 d, 126 d are bonded to one another, thereby securing thelower body portion 132 on top of the floor panel 126.

Referring to FIGS. 29 and 34-38, the upper body portion 134, which ispreferably made of plastic, is formed such that there are two largeopenings 134 a, 134 b therein that correspond to the front and rearcovers 110, 111. It will be understood that the covers may also be sideto side instead of front and back, or the trailer 100 may include morethan two covers. The upper body portion 134 fits onto the lower bodyportion 132 and is received on the indented lip 132 c thereof, therebycooperating to form the overall outer body shape of the trailer 100. Asshown in FIGS. 34-36, and best in FIG. 36, extending around each of thelarge openings 134 a, 134 b is a water diversion trough 180. The trough180 catches and drains any liquids that may get through the spacebetween the closed front or rear cover 110, 111 and the upper bodyportion 134. Seal 108 prevents the liquid caught in the trough 180 fromentering the compartment 118.

An arch portion 134 c spans the top of the upper body portion 134 andextends between and partially defines the large openings 134 a, 134 b ofthe front and rear covers 110, 111. As shown in FIG. 38, the archportion 134 c rests on the mounting surfaces 169 or brackets on themiddle support member 138 b and other portions of the upper body portion134 rest on the support portions 147 of the front and rear supportmembers 138 a, 138 b. It will be understood that because of themechanical connection between the support members 138 (or upper frameportion) and the lower frame portion 136 (via the frame horns 140), asubstantial portion of the weight of the upper body portion 134 isultimately supported by the lower frame portion 136, thereby keeping asubstantial portion of the weight off of the lower body portion 132and/or inner liner 130.

In a preferred embodiment, the plastic components of the main bodyportion 114 (such as the inner liner 130 and the upper and lower bodyportions 134, 132) are secured to one another using an adhesive tape182, such as VHB#4941, which is produced by the 3M Company. This tape182 produces a strong bond between the various components and aids inweatherproofing the interior of the trailer 100.

Referring to FIGS. 39-42, the rear cover 111 is comprised of an outerskin 186, an inner skin 188 and a bar assembly 190 sandwiched ordisposed therebetween. The front cover 110, which, in a preferredembodiment, is not as big as the rear cover 111, is also comprised of anouter skin 186, an inner skin 188 and a bar assembly 190 sandwichedtherebetween. The front and rear covers 110, 111 are secured to theupper body portion 134 by a pair of hinges 184 (described more fullybelow).

In the rear cover 111, the inner skin 188 is formed such that there area plurality of raised portions 188 a therein. The raised portions 188 aare preferably formed in the inner skin 188 (such as by vaccu-forming orthe like); however the raised portions 188 a can also be a material orobject that is adhered to the inner skin 188. Some of the raisedportions 188 a are formed such that the bar assembly 190 can be receivedtherein, as is shown in FIG. 40. The bar assembly 190 can have anycross-sectional shape, for example, square, round, elliptical, etc. Thebar assembly 190 includes mounting brackets 190 a affixed thereto, whichinclude holes 190 c therein and are used to secure the rear hingeportion of the hinges 184 (described below) to the rear cover 111 of thetrailer 100. The outer skin 186 is bonded to the inner skin 188 via glueor the like on the raised portions 188 a of the inner skin 188. Thissandwiches the bar assembly 190 between the inner skin 188 and the outerskin 186. The bar assembly 190 is secured therein preferably with glueand threaded or another attachment method can also be used. The barassembly 190 also includes tabs 190 b that extend from the bar assembly190 toward the latching system 10, as shown in FIGS. 41 and 42. The tabs190 b each include at least one opening 190 c defined therein, throughwhich a threaded fastener 37 is extended, thereby mechanically securingthe latching system 10 (more particularly, the outer shield member 60)and the bar assembly 190 together. It will be understood that the raisedportions 188 a of the inner skin 188 also add stability and strength tothe cover. The inner skin 188 also includes a latch depression 188 b,which is adapted to receive the shaft assembly 14 of the latching system10, and in particular, the outer shield member 60 of the shaft assembly14. The shaft assembly 14 is preferably mounted in the latch depression188 b using a glue, such as a silicone adhesive or methacrylate glue.The shaft assembly 14 can also be secured in the latch depression 188 busing threaded fasteners or the like.

Referring to FIGS. 43-45, the construction of the front cover 110 issimilar to the rear cover 110. The inner skin 188 of the front cover 110also has a plurality of raised portions 188 a formed therein. One of theraised portions 188 a is sized to receive the bar assembly 190. As shownin FIG. 44, the bar assembly 190 is not as large as the bar assembly 190of the rear cover 111, but still preferably includes mounting brackets190 a therein for mounting the front hinge portion of the hinges 184 andtabs 190 b for connection to the latching system 10. The outer skin 186is bonded to the inner skin 188 in a manner similar to that of the rearcover 111. The inner skin 188 also includes a latch depression 188 bsimilar to that of the rear cover 111.

Preferably both bar assemblies 190 are made of steel or other rigidmetal. Both the inner and outer skins 188, 186 are preferably made ofplastic and are sized to correspond to the openings 134 a, 134 b definedin the upper body portion 134. The outer skin 186 of both the front andrear covers 110, 111 has a cavity 186 a formed at the rear edge thereoffor receiving the handle 20 of the latching system 10. The barassemblies 190 are sealed within the inner and outer skins 188, 186 by asilicone adhesive that is placed on the mounting brackets 190 a (flatplates) and a small amount on the square tubular portions.

Referring again to FIGS. 38 and 33a-33 c, the upper body portion 134,lower body portion 132 and inner liner 130 are formed such that they arebonded together to form a reinforcing line around the perimeter of thetrailer 100. The outer wall 130 d of the inner liner 130 extendsupwardly at an angle, terminating in the lip 130 c that runs around theperimeter of the upper edge. In an exemplary embodiment, the outer wall130 d of the inner liner 130 extends upwardly at the front and rear atan angle of 66° (denoted in FIG. 42a as θ) and at the sides at an angleof 84° (denoted in FIG. 42a as φ). It will be understood that angles θand φ can range between about 20° and 90°. The lip 130 c of the innerliner is bonded to the indented lip 132 c of the lower body portion 132.The upper and lower body portions 134, 132 each have generallycurvilinear shapes and meet in a manner such that they are perpendicularto the ground on which the trailer 100 travels, thereby forming a bumperarea 192. The lip 130 c of the inner liner 130 is bonded to the lowerbody portion 132 in this bumper area 192. Because the upper and lowerbody portion 134, 132 and the inner liner 130 are made of plastic, uponimpact of this area, the components will tend to “give” slightly. Theangled outer wall 130 d of the inner liner 130 advantageously allowsgive as well.

When the trailer 100 is backed up, and a jackknife occurs, the bumperportion 192 of the trailer will typically contact the bumper portion ofthe towing vehicle. Due to the advantageous construction of the trailer100 and particularly the bumper portion 192, the trailer 100 willtypically skid along the ground (the friction between the ground and thetires 152 will be overcome) before the trailer 100 or tongue 102 aredamaged.

Referring to FIGS. 46-48c, the hinges 184 are comprised of a middleportion 194, and front and rear hinge portions 196. The middle portion194 preferably has concave ends 194 a for receiving the convex endmembers 196 a of the front and rear hinge portions 196. The middleportion 194 also includes convex end members 194 b that extend from theopposite ends thereof. The end members 194 b each have an opening 194 cdefined therethrough in a lateral direction for receiving a hinge pin200. As shown in FIGS. 48a and 48 c, the middle portions 194 include anopening 194 d defined therein for receiving a set screw 67 or roll pinand securing the hinge pin 200 in place. The middle portion 194 also hasa large opening 202 defined therethrough for accommodating racks orropes for tie-downs and the like. Threaded holes 194 e are defined inthe bottom of the middle portion 194 for receiving threaded fasteners 37and thereby securing the middle portion 194 to the hinge mounting flats134 d on arch portion 134 c. The threaded fasteners 37 are received inopenings 169 a in the mounting surface 169 and the arch portion 134 cand the middle portion 194 of the hinge 184.

The front and rear hinge portions 196 are preferably formed in the shapeof a wedge having a curved upper surface and have a large opening 204defined therethrough for accommodating racks or tie-downs and the like.At the end adjacent the middle portion 194, the front and rear hingeportions 196 have opposed convex members 196 a extending therefrom thatare adapted to cooperate with the end member 194 b of the middle portion194. The opposed convex members 196 a have openings 196 b definedtherethrough for receiving the hinge pin 200. The end members 194 b ofthe middle portion 194 are received between the opposed convex members196 a of the front and rear hinge portions 196, and the openings 194 cand 196 b in each are aligned and the hinge pins 200 are receivedtherein to form a pivotable hinge. It will be understood that theconcave—convex relationship of the ends of the middle portion and thefront and rear hinge portions 196 can be reversed. In a preferredembodiment, bushings 206 are press fit into the openings 196 b of thefront and rear hinge portions 196, and are adapted to receive the hingepins 200. The bushings 206 can also be secured in the openings 196 busing a glue or other adhesive. Threaded holes 196 c are defined in thebottom of the front and rear hinge portions 196 for receiving threadedfasteners and thereby securing the front and rear hinge portions 196 tothe front and rear covers 110, 111, respectively. The threaded fasteners37 that secure the front or rear hinge portions 196 in place arereceived in openings in the brackets 190 a on the bar assemblies 190 ofthe front and rear covers 110, 111, and openings 186 b in the outer skin186 of the front and rear cover 110, 111 and the front or rear hingeportion 196.

In a preferred embodiment, the middle portion 194 and front and rearhinge portions 196 of the hinge 184 are made using an extrusion process.However, this is not a limitation on the present invention.

As discussed above, a number of the components of the trailer 100 arepreferably made of plastic and a number of the components are preferablymade of steel or other metal. Metals, such as steel, and plastic havevery different thermal coefficients of expansion. Therefore, in apreferred embodiment, the trailer is designed to allow the plasticcomponents to expand and contract while the steel frame remainssubstantially rigid. More generally, the trailer is designed such thatthe inner frame and the outer shell have different thermal coefficientsof expansion, wherein the components of the outer shell expand andcontract while the inner frame remains substantially rigid. Typically,the inner frame has a lower thermal coefficient of expansion that theouter shell.

To allow the elements of the outer shell to expand, while maintainingthe rigidity of the inner frame, the main body portion 114 of thetrailer includes spacers 222 located at those points where plastic issandwiched between two metal components that are secured by a threadedfastener. Preferably the spacers 222 are made of metal. To accommodatethe spacers 222, the holes or openings for the threaded fasteners madein the plastic components are oversized compared to the holes oropenings made in the metal components. The spacer 222 is sized to fit inthe hole in the plastic component, rests on the metal component, and hasan opening therein that corresponds in size to the opening in the metalcomponent. FIG. 49 demonstrates this concept. FIG. 49 is a top plan viewof where the front and rear covers 110, 111 are hinged to the archportion 134 c with the hinge 184 omitted. As shown, the openings 134 ein the arch portion 134 c and the openings 186 b in the front and rearcover portions 110, 111 are larger than the corresponding openings 169 ain the mounting brackets 169 and 190 a. A spacer 222 is shown in theopening 186 b in the outer skin 186 of the rear cover 111. The spacer222 spaces the mounting bracket 190 a from the rear hinge portion 196 ofthe hinge 184. This keeps the hinge 184 from clamping onto the plasticof the outer shell 186, thereby allowing the plastic to expand andcontract as necessary. As shown in FIG. 49, the opening 186 b (andsimilar openings in the other plastic components) is bigger than thespacer 222. This also allows the plastic to expand and contract asnecessary. Generally, frame 122 and its members and other parts of theexternal hardware are held in rigid assembly by threaded fasteners 37 or41. The spacers 222, which are preferably made of metal, are used toallow movement of the plastic parts as they react to thermal expansionand contraction while sandwiched between assembled metal parts. It willbe appreciated by those skilled in the art that the thermal change inthe plastic parts most significantly affects length and width dimensionsof plastic parts. Therefore, as described above, the holes or openingsin plastic parts are typically oversized to further allow for thermalmovement. Spacers 222 may be used, for example, in cavity 186 a, wherethe latching system 10 is secured to the front and rear covers 110, 111,and in latch depression 188 b between the outer shield portion 60 andthe tab 190 b with the inner shell 188 sandwiched therebetween (as shownin FIG. 41) and, between the attachment plates 142 and the lower framemember 136 with the floor panel 126 sandwiched therebetween (as shown inFIGS. 33b-33 c), and between the keeper 16 and the support portion 147or the support members 138, with the upper body portion 134 sandwichedtherebetween (as shown in FIG. 33c).

Referring to FIGS. 50-61, the front and rear covers 110, 111 each have aprop rod 208 associated therewith. It will be understood that the proprods are referred to generically as 208, the front prop rod is referredto as 208 a and the rear prop rod is referred to as 208 b. The prop rods208 are used to hold the front and rear covers 110, 111 in theirrespective open positions. The prop rods 208 are stowed on the undersurface of the front and rear covers 110, 111. The front prop rod 208 ais stowed in a position substantially parallel to the elongated shaft 62of the latching system 10 and the rear prop rod 208 b is stoweddiagonally across the rear cover 111. However, these are not limitationson the present invention.

The prop rods 208 preferably comprise an elongated rod 208 c having aball joint 208 d with a threaded stud 208 e at one end and a hook 208 fat the opposite end (as best shown in FIG. 60. In another preferredembodiment, instead of a ball joint, the prop rod 208 may include a loopthat can be secured to an eye bolt, thereby allowing pivotal motion, asshown in FIG. 58. The hook 208 f is adapted to engage one of the keepers16 that is affixed to the sill 112 of the upper body portion 134. In apreferred embodiment, the inside surface of the hook has notches 208 gthat cooperate with the tubular portion 81 of keeper 16.

As shown in FIGS. 50-51, to secure the front prop rod 208 a to the frontcover 110, an attachment plate 210 is secured (by threaded fasteners orrivets) to the inside surface of the inner skin 188. The attachment/wearplate 210 includes a mounting bracket 210 a for receiving the eye bolt221 associated with prop rod 208 a.

As shown in FIGS. 55, 56 and 61, to secure the rear prop rod 208 b tothe rear cover 111, a mounting bracket 212 that is unitary with the barassembly 190 (and which protrudes through the inner skin 188) has anopening for receiving the threaded stud of eye bolt 221. The wear plate210 (as shown in FIG. 57) protects the plastic from wear that couldresult from operations or movement of the prop rod 208 b.

As shown in FIGS. 52, 53 and 57, a plurality of rod securing hooks 214for holding the prop rods 208 in the stowed position are secured to theinner skin 188 of both the front and rear covers 110, 111. In apreferred embodiment, the front cover 110 includes two rod securinghooks 214, one adjacent the hook 208 f of the prop rod 208, and a secondnear the center of the elongated rod 208 c. The rear cover 111preferably includes one rod securing hook 214 and a skid plate 215Preferably, the mounting brackets 210 a/212, rod securing hooks 214 andskid plate 215 are arranged such that the prop rod 208 is held intension when it is in the stowed position, as shown in FIGS. 50 and 55.This helps prevent the rod 208 from falling out during travel, etc.

In use (the front or rear cover must be open), the prop rod 208 isdetached from the rod securing hooks 214, pivoted downwardly and engagedwith the associated keeper 16. Because the prop rod 208 is pivoteddownwardly and the hook 208 f engaged within a keeper 16 below the cover(typically a prop rod is pivoted upwardly), disengagement by wind forceraising the open cover is resisted. The hook 208 f has an end that isturned up. This further prevents disengagement by wind force.

It will be understood that the majority of the components of the mainbody portion 114 of the trailer 100 are comprised of plastic to make thetrailer 100 lightweight and durable. However, constructing the trailer100 components of plastic is not a limitation on the present invention.Any sufficiently rigid material can be used.

Referring to FIGS. 62-64e, in a preferred embodiment, the trailer 100includes a low current, tow vehicle-powered supplemental lighting system216. In this embodiment, each “light” 172 (meaning brake light, turnsignal light, running light, etc.) is comprised of a plurality ofclosely positioned light emitting diodes (LEDs) 218. LEDs 218 reduce thecurrent draw from the towing vehicle 178. For example, the LED “lights”can reduce current draw by as much as 76%. This may circumvent the needfor adapters as described above in the Background of the Inventionsection. This lighting system 216 offers benefits applicable totrailers, hitch-mounted utility carriers and any other type of equipmentthat includes supplemental lighting powered by a host vehicle. In apreferred embodiment, the tail/stop/turn lights 172 a, side markerlights 221 and license lights 172 c can be incandescent lights as isknown in the art.

In another embodiment, a brake light, turn signal and taillight may beincorporated in one LED light assembly. In this embodiment, differentarrangements of the separate LEDs 218 within a field of LEDs will lightup to indicate braking, turning or lights running (taillight function).An example is shown in FIGS. 63a and 63 b. In this example, wouldfunction as taillights. Turn indication could be all of the LEDs maylight up to indicate braking, while only half may light up to indicatethat the lights are running.

The embodiments of the present invention recited herein are intended tobe merely exemplary and those skilled in the art will be able to makenumerous modifications to them without departing from the spirit of thepresent invention. For example, the trailer could be redesigned toinclude a single wheel for towing behind a motorcycle; the trailerinterior compartment 118 can be divided up into multiple compartments;the hinges can be one sided (i.e., either the front or rear hingeportion 196 can be omitted). For the latching system, a single hook andkeeper can be used; the hook or hooks may not be disposed at the ends ofthe elongated shaft; the beak member 24 and torsion spring 39 may beomitted; the keepers can be an opening defined in the vehicle base; theshield 60 may be omitted and the latch plate assembly and elongatedshaft may be affixed directly to the vehicle cover; the rotator clevismay be a tube or a pair of tubes that are engaged by the latch lever.All such modifications are intended to be within the scope of thepresent invention as defined by the claims appended hereto.

What is claimed is:
 1. A trailer comprising: a lower frame portion, said lower frame portion including at least one axle having wheels at its opposite ends, a lower body portion supported on said lower frame portion, wherein said lower body portion has a lip extending inwardly from a bottom edge thereof, an upper frame portion extending upwardly from said lower frame portion, an upper body portion supported on said upper frame portion and affixed to said lower body portion, and a floor panel disposed between said lower frame portion and said lower body portion, said floor panel having a lip extending around at least a portion of the perimeter thereof that is affixed to said lip of said lower body portion.
 2. The trailer of claim 1 wherein a deck is disposed between said lower frame portion and said floor panel.
 3. The trailer of claim 2 wherein said deck is comprised of wood.
 4. The trailer of claim 1 wherein said floor panel has at least two wheel cavities defined therein, wherein said floor panel has at least two wheel housings secured thereto, and wherein said wheel cavities and said wheel housings cooperate to partially surround the wheels.
 5. The trailer of claim 1 wherein said lower frame portion includes a plurality of frame horns affixed thereto, and wherein said upper frame portion extends upwardly from said frame horns.
 6. The trailer of claim 5 wherein said upper frame portion includes a middle support member extending upwardly from at least two of said frame horns.
 7. The trailer of claim 5 wherein said upper frame portion includes front, middle and rear support members each extending upwardly from at least two of said frame horns.
 8. The trailer of claim 7 wherein said front and rear support members each include two spaced apart upright frame members and a support portion extending therebetween, said upright frame members being affixed to said frame horns.
 9. The trailer of claim 7 wherein said front, middle and rear support members are removably affixed to said frame horns. 